ECC's crushing plants operate with 2x2 stage crushers supplying 1400 t/hour limestone/clay mixture and 1200 t/hour of high grade limestone. The control room operates the two crushers. The limestone quarry is located in the vicinity of the crushing plant therefore minimizing the cost. This quarry is to last 70 years. Silty Clay is transported from ECC’s own reserve some 50km away, expected to last 30 years. After crushing, the limestone/clay mixture is transported by belt conveyor some 600m to two 60,000 t circular storage, both equipped with centralized stackers and reclaimers. High-grade limestone is crushed, transported and stored in a 12,000 t longitudinal store. Corrective materials are introduced and stored in the longitudinal stores, where there is a space for a total of 10,000 tons per store. Extracted raw materials are transported by belt conveyors to the feed bin buildings. Each feed bin building houses bins for mixtures, sand, iron ore and high-grade limestone. Control of proportioning is achieved by weight feeders, all transfers are fully de-dusted with bag filters. The raw mill is designed by Polysius with a capacity rated at 400 tons per hour. The mill is equipped with high efficiency separator and separating cyclone for finished raw meal. It is de-dusted by the main ESP supplied by Lurgi. Raw mill product is pneumatically transported to a single 16,000 ton continuous homogenizing silo to be fed to the pre-heaters. Kilns are equipped with a five-stages string Polysius DOPOL pre-heater with a pre-calciner. The process line is equipped with a 43% chloride bypass including a separate ESP and a conditioning tower before inlet. The kiln is 76m long, and 5.2/4.6m, supported by three rollers stations, and fitted with loose kiln tires. Kiln firing is by natural gas 95% and heavy oil 5%; the pre-calciner is fired by natural gas as well, but with heavy oil support. The Polysius REPOL grate cooler that has been modified to meet the capacity upgrade of the plant is also de-dusted with a Lurgi electrostatic precipitator. Kiln production is now nominally rated at 5500 t/day. Clinker is transported by pan conveyor to a 50,000 t circular storage. The mills needed for cement production are 6 all in all; four of them are 110 t/hr and the other two left are 220 t/hr each as a nominal capacity. Large Mills are powered by twin combi-flex drives of 3,900 kw and equipped with high efficiency SEPOL separators and bag houses for finished products. Cement is transported pneumatically to four silos of 20,000t storage capacity silo and another further four with 10,000 t storage capacity silos.
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	MANUFACTURING PROCESS :
	ECC has adapted a management process system, where each process is fully responsible for its own role and for serving the other processes:
	Quarries ECC operates several quarries, the main ones being for limestone and clay.Many manufacturing tools are used, including dump trucks, excavators, drilling machines. Moreover, loaders are gathered, managed and maintained to assure the blasting and crushing of 12 million tons of cement raw materials per year, mainly limestone and clay. Clinker Manufacturing The raw meal is fed to the pre-heater tower where it cascades, and then fed to the kiln where it reaches 1440 C’; at this burning zone, the clinker occurs. The clinker coming out of the kiln drops into in a cooler, and conveyor belts pull them to a circular storage. Cement Grinding and Packing The clinker produced in the previous process is transported to cement mills by conveyor belts. Horizontal steel tube filled with steel balls is the concept of those grinding mills that grind the clinker into the first form of what is to be named Portland cement. A fine grey powder is formed to be mixed with certain amounts of gypsum and other additives in several other grinding steps to reach the desired fineness and standard mix. Depending upon the market requirements, the cement is loaded in bulk through 12 bulk loading facilities with a capacity of 12,000 tpd or packed in 50 kg bags with the help of 12 rotary packers with a capacity of 100 tph each, loaded on to trucks and finally dispatched to the required destinations. Quality, Environment and Safety ECC cement specifications widely exceed those set by BS, ASTM, EN and Egyptian Standards. Our Mission Statement: ECC’s vision is focusing on giving equal attention to the environment as well as safety, production, quality, morale and cost; keeping in mind that the highest performance we are expecting from our operations is measured by the minimum standards we are applying and maintaining. Engineering This process covers four main activities: Engineering activity, plant infrastructure, plant utilities & maintenance & industrial workshop. Maintenance and Material Planning This process is recently developed to centrally manage the maintenance and material planning aspects.
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